Apparatus for cell construction



1963 J. v. CARLISLE ETAL 3,111,769

APPARATUS FOR CELL CONSTRUCTION 2 Sheets-Sheet 1 Filed Nov. 21, 1960 COLLECTOR SUPPORT-FRAME COLLECTOR- FRAME SUB- ASSEMBLY INVENTORS JA MES M CARL/5L5 rnsooanz u. Afi/VOL n COMPLETE BASE ASSEMBLY N v- 6, 1963 J. v. CARLISLE ETAL 3,111,769

APPARATUS FOR CELL CONSTRUCTION Filed Nov. 21, 1960 2 Sheets-Sheet 2 FIG. 2

INVENTORS JAMES V. CARL/8L5 By THEODORE M. AHA/0L0 ATTORNEY United States Patent 3,111,769 APPARATUS FOR CELL CONTRUTIUN .laines V. Cariisie, Eaton Rouge, 1a., and Theodore M.

Arnold, Punta Gorda, Fla, assignors to Ethyl Corporation, New York, N.Y., a corporation of Virginia Filed Nov. 21, 1960, Ser. No. 70,801 1 Claim. ((ll. 33-180) This invention pertains to a new and novel apparatus for the construction of electrolytic cells.

This application is a continuation-in-part of prior pa out applications Serial No. 493,156, filed March 9, 1955 (now US. Patent 2,912,750, issued November 17, 1959) and Serial No. 715,171 filed January 30, 1958 and has matured into Patent No. 3,009,239 granted November 21, 1961,

The manufacture of sodium and other alkali metals is carried out in an electrolytic cell which is basically similar to the Downs cell described in US. Patent 1,501,756. Briefly, the cell includes a housing containing one or more anodes each of which is surrounded by a cylindrical cathode. In the annular space between an anode and the surrounding internal surface of the cathode is positioned a foraminous diaphragm supported from above by what is commonly referred to as the collector. The collector, or collector portion corresponding to a single anode comprises an outlet port for removal of the gaseous halogen and an annular inverted channel for manifolding and removal of the alkali metal. This collector is supported by a frame which in turn is attached to and supported by the cell housing.

'The concentricity and vertical disposition of the anodes with the surrounding diaphragm and cathode surface is an important attribute of a properly constructed cell. Attaining this objective has been a long standing problem in the industry. Inherent dimculties in the construction of these cells has been the lack of a suitable method for positioning the cathode, with respect to the anode, and for positioning the diaphragm located in the annular space between each anode and cathode. Because of the fact that the cathode and the diaphragm surround substantially the entire length of the anode, it is quite difficult to position the diaphragm in between the cathode and anode within proper tolerances so as to provide the most efiicient construction of the cell for operation. This can be appreciated when it is noted that ordinarily the lateral distance between the anode and cathode is of the order of only 1 /2 inches and for best operation the diaphragm must be inserted equidistant from the anode and cathode over the entire length of the anode, which is about 3 to 4 feet or more in length. Prior methods employed for achieving this result have not been adequate. Generally speaking, the life period, that is the period before the cell need be broken down for rebuilding, has been erratic and necessitated completely dismantling the cell to replace the diaphragms. Such dismantling and reconstruction, in addition to being inherently expensive, also results in reducing production capacity of a plant. This arises from the fact a shop or plant has a certain number of stalls or locations for occupancy by as many cells; when a cell is being torn down and rebuilt, it is then not possible to merely insert a spare into that operating space.

Until the present invention, the techniques in cell building left much to be desired, as above explained. Consequently, it is an object of the present invention to provide apparatus for the rapid and accurate construction of an electrolytic cell. A further object of this invention is to provide apparatus to be employed in constructing an electrolytic cell which will provide a cell having a longer life, higher emciency, and increased productivity. Another object of the present invention is to provide apparahis for the accurate positioning of a plurality of anodes within a cell base. A particular object is to provide apparatus for assembling anodes upon a cell base in precise vertical alignment, one anode with respect to the other, so that when the anode-cell base sub-assembly is formed into a larger sub-assembly the anodes will be positively aligned in the desired final configuration. Other objects will be apparent from the discussion hereinafter.

The apparatus of the present invention is capable of assuming a variety of forms, and can be used in conjunction with other apparatus, as will be readily understood from the details given hereinafter and in the accompanying figures wherein,

FIGURE 1 shows in exploded fashion the major components of a cell, the sequence of assembly of the components into a completed cell, and the relation of the apparatus of the present invention to other apparatus and to the several major components or sub-assemblies of a cell, and

FIGURE 2 is an isometric view of a jig apparatus hereafter identified as Jig C, which provides for aligning the cell anodes with respect to each other and with respect to the base of the cell, said view showing the anodes in operative relations to the Jig C.

The apparatus employed in the formation of a base assembly for a cell pursuant to the present invention comprises a member having a plurality of apertures terminating upon a common plane. The apertures are arranged in plan and correspond at least in number to the anodes of a completed cell. Each aperture is of larger cross-sectional diameter than the cross-sectional diameter of an anode and is provided with circumferentially uniformly spaced guides which constrict the effective diameter size of the aperture to correspond to the diameter of a cell anode. In using this apparatus an anode is simultaneously received within each of the apertures and upper end of each anode is brought into a position flush with the terminal portions of each of the apertures, this being conveniently done by blocking the terminal portions of each of the apertures with a solid member so that an anode cannot extend beyond the plane upon which the aperture is terminated.

It has been found that the apparatus of this invention, particularly in combination with other apparatus, provides an efficient means for the construction of an electrolytic cell whereby the criticality of the positioning of the cathode with respect to the anodes, and the diaphragms with respect to the cathode and anodes, is achieved. The apparatus eliminates incorrect alignment of these integral parts which results, for example, in burning of the diaphragms and thus causing loss of production and unnecessary dismantling of the cell, which must be reconstructed. By the use of the apparatus of this invention, the efiicien'cy of the cell is considerably increased as evidenced by the fact that production is increased for a given current input. In addition, the average life of the diaphragm is appreciably increased, thereby reducing loss in production time.

The construction of a completed cell includes two major assembly sequences, the assemblies so-made then being combined into a completed cell. One sequence of assembly operations permits formation of the lower portion of a cell. This sequence of operations thus provides for the formation of a complete base assembly by the addition of anodes to a cell base, then for the addition of a cell shell portion, then for the addition of a cathode, then for the addition thereto of an upper or final cell shell portion, thus completing this major assembly.

Another sequence of assembly operations includes assembly of a collector and collector support frame to form a sub-assembly, and then the addition of diaphragm screens to that sub-assembly to form the upper portion of i 9 a cell, the second of the two major assemblies. These two assemblies are then combined to form a completed cell.

This entire sequence of assembly operations is schematically illustrated by reference to FIGURE 1 which shows the How of separate cell components into subassemblies and the relationship of these components and sub-assemblies to the figures of the present invention. Referring to FIGURE 1, a set of anodes and a cell base are combined, using Jig C. The base assembly thus formed is then combined with a cell shell portion. A part of the cell lining is then added, and a cathode is then fitted to this base sub-assembly using a Jig D to provide proper spatial relations. To this assembly is then added an upper cell shell using Jig E for correct alignment. This sequence of operations completes the formation of one of the two major assemblies, viz., the formation of a complete base assembly, or the lower portion of a cell.

The other major sequence of assembly operations involves firstly the combination of a collector and collector support frame into a sub-assembly, using Jig A. This subassembly and a set of diaphragms are then combined by the use of another apparatus, Jig B. This completes the second major sequence of operations and provides for the formation of a collector-collector frame-diaphragm assembly, the upper portion of a cell. This assembly is then transported in a transport Jig F and is combined with the base assembly to form a completed cell.

The apparatus, Jig C, employed for combining the anode sticks with the base assembly, shown in FIGURE 1, is described by reference to FIGURE 2. FJGURE 2 shows in detail, Jig C, which is used for accurate positioning of the anodes within the cell base. A set of anodes 131 131 131 131 are adjustably positioned on a previously constructed cell base and Jig C placed over the anodes. The anodes 13.1 generally are precisely machined graphite cylindrical members having accurately squared ends. The cell base provides a horizontal surface so that merely setting the anodes 131 in place provides substantially vertical alignment. The Jig C includes a unitary base member 132, having four mating apertures of slightly larger diameter than, but otherwise corresponding to, the anodes. Guides 133 uniformly positioned on the interior surfaces of the said apertures force the anodes 131 131 13 1 131 into precise alignment one with the other and also maintain this alignment of the anode sticks 131. In other words, in using the apparatus the positions of the anodes 131 are adjusted slightly until the anodes 131 are fitted into the mating apertures of Jig C. At this time Jig C is slided downwardly over the four anodes until its downward movement is stopped by the transverse bars 134,, 134 which come to rest against the upper ends of the anodes 131. The horizontal disposition of the Jig C is adjusted by appropriate shims between the cross bars 13 2 134 and the tops of the anodes when necessary to provide a horizontal disposition. This compensates for minor irregularities in the length or top surfaces of the anodes 131 131 13 1 13:1 It is seen that the anodes are then positively aligned in the desired final configuration with respect to each other. The position of the anodes is made permanent by mortaring and casting of suitable plastic refractory at the base of the anodes within the cell base, shown only in FIGURE 1. Upon the setting of this refractor Jig C is removed.

The base assembly thus formed is then ready for the addition of the first portion of a cell shell upon which J: is then fitted a cathode assembly. After positioning of the cathode assembly, the cell shell is completed. The lower portion of a cell thus completed is then ready for assembly with an upper cell assembly to form a complete cell.

From the foregoing, it is seen that the use of various apparatus provides for the construction of a cell having a continuous explicit relationship between the collector frame, collector, diaphragms, anodes, and other portions of a cell. These relationships are established and preserved from the beginning of construction through to the final assembly step. vFurther steps to render a cell operable after assembly of a complete base assembly with a collector-collector frame-diaphragm assembly would include the connection of an appropriate chlorine line to the collector opening, and the attachment of the necessary electrical connections, etc.

In careful comparison of the performance of a group of cells constructed with the apparatus of our invention with performance of a group constructed according to previous methods it was found that the former group provided an increase of approximately 1.5 percent in current efficiency. In addition, it was found that the average effective life of the former group of cells was a significant improvement over the preceding practice, particularly with respect to the diaphragm life. Since the cost of construction of cells with the present apparatus is substantially the same as by the former practices, it is apparent that our apparatus is highly beneficial and economical.

Having described the apparatus of our invention in some detail and the manner of its use, What we claim is:

In the construction of a sodium electrolytic cell, said cell comprising 4 anodes afiixed in and upon a cell base to form a cell sub-assembly, said anodes being mounted in said cell base in a prearranged fixed spaced relationship, the improvement comprising: an apparatus for the accurate vertical alignment of said 4 anodes further comprising:

(l) a unitary base member having 4 apertures therein, the longitudinal axes of said apertures being parallel to each other and extending in a vertical direction when said base member is horizontally oriented in its operable position, said base member being further defined in that the apertures therein are arranged in a fixed spaced relationship such that the longitudinal axes of the apertures are coexistent with the longitudinal axes of the anodes when said base member is positioned relative thereto in the construction of a cell sub-assembly,

(2) said unitary base member further comprising 4 guide members uniformly spaced Within the apertures and extending longitudinally therein so as to facilitate the insertion and accurate positioning of the anodes within the apertures in the construction of a cell sub-assembly,

(3) said unitary member further comprising crossbars positioned on the top of said member and extending across the apertures in said member to serve as a means of supporting said member upon said anodes when placed thereupon to accurately vertically align said anodes in the construction of a cell sub-assembly.

Bailey et al Oct. 27, 1931 Wolcott Dec. 15, 1953 

